Tilt-Wall Panel

ABSTRACT

Embodiments of a panel for use in building a tilt-wall building are disclosed, some of which comprise a plurality of structural studs, each comprising: a baseplate; an exterior-facing sidewall and an interior-facing sidewall connected by the baseplate; and a tab punched out of each of the sidewalls; an exterior concrete surface in which the tabs punched out of the exterior-facing sidewalls are embedded; and an interior concrete surface in which the tabs punched out of the interior-facing sidewalls are embedded; where the exterior and interior concrete surfaces are substantially planar surfaces that are substantially parallel to each other. Methods for forming tilt-wall panels are also disclosed.

CROSS-REFERENCE(S) TO RELATED APPLICATION(S)

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 61/080,632 filed Jul. 14, 2008, the entire contents of whichare hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to the field of buildingconstruction. More particularly, the present invention relates todevices and methods for building a tilt-wall building.

2. Related Art

The building and construction industry has previously employed atechnique for forming walls in which structural studs are embedded inconcrete to form tilt-wall panels, which are then lifted into place toform the walls of tilt-wall buildings. A primary challenge in creatingtilt-wall panels is to embed the studs in concrete in such a way as tominimize or eliminate any separation between the studs and the concreteonce the panel is formed and lifted into place. One means of addressingthis challenge has been through the design of the structural studsthemselves.

U.S. Pat. No. 6,151,858 to Ruiz, et al. (“Ruiz”) discloses an example ofone such design for a structural stud. The stud disclosed in Ruiz has anumber of tabs extending outwardly from the sidewalls of the stud, andeach of the tabs is derived as a cut-out portion of the sidewall. Thetabs are L-shaped and are folded out from the sidewall along a bend linethat is generally at right angles to the longitudinal axis of the stud.One problem with the machinery needed to form the tabs in Ruiz is thattwo strikes are required to form the tabs: one strike to punch the tabout of the sidewall and another strike to form the L-shape in the tab.

U.S. Publication No. 2005/0055967 to Kariakin (“Kariakin”) discloses anexample of another design for a structural stud. Kariakin describes anumber of problems with the design disclosed in Ruiz, including that theL-shaped tabs are difficult to punch out from the sidewall of the studdue to the extreme right angle required which joins the two legs of theL-shape together. Kariakin also discloses that another problem with theL-shaped tab design is that the surrounding concrete does not completelyengage the tab surface area, particularly around the right angle joint.Kariakin attempts to overcome these problems by employing tabs that aresubstantially curved in side elevational view such that the tabs arehalf U-shaped. The tabs in Kariakin are said to be formed by means of arolling guide with a punch that pierces a portion of the sidewall inorder to force the section outward to define the tab.

U.S. Publication No. 2007/0245657 to Valle, et al. (“Valle”), thecontents of which are incorporated herein by reference in theirentirety, discloses a structural stud that (1) provides improvedadhesion between the stud and the surrounding concrete such thatseparation between the stud and the concrete is further minimized incomparison to the examples disclosed above and elsewhere in the priorart, and (2) can be formed by a device and a process that is lessexpensive and has less problems than the devices and processes by whichother studs are formed. In certain embodiments, the structural stud ofValle comprises a stud having a sidewall and a tab punched out of thesidewall, the tab comprising: a tab leg that is substantially planar andis connected to the sidewall at one end of the tab leg, and thatprojects outwardly from the sidewall at an angle of less than ninetydegrees to the sidewall; and a tab foot extending from the tab leg andcurving either away from or toward a hole in the sidewall created by thetab punched out of the sidewall.

Tilt-wall building techniques have traditionally been used primarily fornon-industrial buildings such as schools, office buildings, and retailstores. For such buildings, it is acceptable to form the tilt-wall panelin such a way that the side of the panel that serves as the exteriorwall of the building is a uniform surface of concrete, while theinterior side of the panel is open to reveal the structural studs usedto form the panel. Leaving the interior side of the panel open allowsfor plumbing, electrical, and insulation materials to be installedinside the wall before traditional interior wall materials such assheetrock and drywall are applied to the interior side of the panel tocreate a uniform interior wall surface.

Conventional tilt-wall building techniques have found less applicationfor industrial buildings such as warehouses and manufacturingfacilities. Industrial buildings often require a more rugged interiorwall surface than is provided by sheetrock and drywall, due tocollisions that can occur between heavy machinery (such as forklifts)and the interior wall surface. To provide a rugged interior wallsurface, some in the industry have attempted to create tilt-wall panelshaving a concrete interior surface that is similar to the concreteexterior surface found on traditional tilt-wall panels. To create suchpanels, three to four inches of concrete are required for each of theinterior and exterior surfaces in order to give the panel sufficientrigidity and structural integrity to withstand the tilt-wall liftingprocess and other forces imposed on the panel after it is lifted intoplace, and a number of pins are used to attach the interior surfaceconcrete to the exterior surface concrete. In between the two concretelayers are two layers of re-bar (one for the interior surface concreteand one for the exterior surface concrete) and a two-inch layer of rigidboard insulation. Such insulation is expensive compared to other typesof insulation, but it is necessary to offset the high thickness andweight of the three to four inch concrete layers used for the interiorand exterior surfaces.

What is needed is a tilt-wall panel for use in industrial buildings thatprovides a concrete interior surface and yet is lighter in weight,easier and less expensive to make, better insulated, and better suitedto being used in the taller walls of industrial buildings than priortilt-wall panels providing a concrete interior surface, and that has thebenefit of improved adhesion between the studs used in the tilt-wallpanel and the surrounding concrete.

The referenced shortcomings are not intended to be exhaustive, butrather are among many that tend to impair the effectiveness ofpreviously known techniques for designing structural studs and tilt-wallpanels; however, those mentioned here are sufficient to demonstrate thatthe methodologies appearing in the art have not been altogethersatisfactory and that a significant need exists for the techniquesdescribed and claimed in this disclosure.

SUMMARY

Embodiments of the present invention include an improved tilt-wall panelthat provides a concrete interior surface and yet is lighter in weight,easier and less expensive to make, better insulated, and better suitedto being used in the taller walls of industrial buildings than priortilt-wall panels providing a concrete interior surface. A furtherbenefit of the tilt-wall panels of certain embodiments of the presentinvention is that the structural studs used therein have the benefit ofimproved adhesion between the studs and the surrounding concrete.

In certain embodiments, the tilt-wall panel of the present inventioncomprises: a plurality of structural studs, each comprising: abaseplate; an exterior-facing sidewall and an interior-facing sidewallconnected by the baseplate; and a tab punched out of each of thesidewalls, each tab comprising: a tab leg that is substantially planarand is connected to the sidewall at one end of the tab leg, and thatprojects outwardly from the sidewall at an angle of less than ninetydegrees to the sidewall; and a tab foot extending from the tab leg andcurving either away from or toward a hole in the sidewall created by thetab punched out of the sidewall; where the structural studs are arrangedsuch that their baseplates are substantially parallel to each other andvoids are formed between successive structural studs; an exteriorconcrete surface in which the tabs punched out of the exterior-facingsidewalls are embedded; and an interior concrete surface in which thetabs punched out of the interior-facing sidewalls are embedded; wherethe exterior and interior concrete surfaces are substantially planarsurfaces that are substantially parallel to each other.

In some embodiments, one or more of the holes is defined by a base sideand a top side, the base side has a greater length than the top side,and the tab leg extends from the base side. In other embodiments, one ormore of the structural studs comprises a plurality of tabs. In oneembodiment, the plurality of tabs is spaced such that the gap betweensuccessive tab leg connections to the sidewall is less than about sixinches. In another embodiment, the gap between successive tab legconnections to the sidewall is about four inches.

In certain embodiments, the tilt-wall panel further comprises aninsulation material in the voids formed between the structural studs. Inother embodiments, the tilt-wall panel further comprises a rubberizedinsulation material applied to the tabs punched out of theexterior-facing sidewalls of the structural studs before the tabs wereembedded in concrete. In still other embodiments, the tilt-wall panelfurther comprises a radiant barrier wrapped over the tabs punched out ofthe exterior-facing sidewalls of the structural studs before the tabswere embedded in concrete. In yet another embodiment, the tilt-wallpanel further comprises wire mesh laid over both sidewalls of thestructural studs before the tabs punched out of the sidewalls wereembedded in concrete. In other embodiments, the tilt-wall panel furthercomprises lifting anchors and/or support anchors laid in the voidsformed between the structural studs prior to embedding the tabs inconcrete, such that a portion of each lifting anchor and/or supportanchor is exposed in one or both of the concrete surfaces.

In certain embodiments, the present invention comprises a method ofbuilding a tilt-wall panel, comprising: obtaining a plurality ofstructural studs, each stud comprising: a baseplate; an exterior-facingsidewall and an interior-facing sidewall connected by the baseplate; anda tab punched out of each of the sidewalls, each tab comprising: a tableg that is substantially planar and is connected to the sidewall at oneend of the tab leg, and that projects outwardly from the sidewall at anangle of less than ninety degrees to the sidewall; and a tab footextending from the tab leg and curving either away from or toward a holein the sidewall created by the tab punched out of the sidewall;arranging the structural studs such that their baseplates aresubstantially parallel to each other and voids are formed betweensuccessive structural studs; forming an exterior concrete surface inwhich the tabs punched out of the exterior-facing sidewalls areembedded; and forming an interior concrete surface in which the tabspunched out of the interior-facing sidewalls are embedded; where theexterior and interior concrete surfaces are substantially planarsurfaces that are substantially parallel to each other.

In some embodiments, the method further comprises laying lifting anchorsand/or support anchors in the voids formed between the structural studsprior to embedding the tabs in concrete, such that a portion of eachlifting anchor and/or support anchor is exposed once the concretesurfaces are formed. In other embodiments, the method further comprisesplacing an insulation material in the voids formed between thestructural studs. In still other embodiments, the method furthercomprises applying a rubberized insulation material o the tabs punchedout of the exterior-facing sidewalls of the structural studs prior toembedding the tabs in concrete. In yet another embodiment, the methodfurther comprises, wrapping a radiant barrier over the tabs punched outof the exterior-facing sidewalls of the structural studs prior toembedding the tabs in concrete. In other embodiments, the method furthercomprises laying wire mesh over both sidewalls of the structural studsprior to embedding the tabs punched out of the sidewalls in concrete.

In certain embodiments, the tilt-wall panel of the present inventioncomprises a plurality of structural studs, each comprising: a baseplate;an exterior-facing sidewall and an interior-facing sidewall connected bythe baseplate; a vertical tab punched out of each of the sidewalls and avertical hole resulting from the vertical tab, the tab comprising: a tableg that is substantially planar and is connected to the sidewall at oneend of the tab leg, and that projects outwardly from the sidewall at anangle of less than ninety degrees to the sidewall; and a tab footextending from the tab leg of the vertical tab punched out of thesidewall and curving either away from or toward the vertical hole in thesidewall resulting from the vertical tab punched out of the sidewall;and a horizontal tab punched out of each of the sidewalls and ahorizontal hole resulting from the horizontal tab, the tab comprising: atab leg that is substantially planar and is connected to the sidewall atone end of the tab leg, and that projects outwardly from the sidewall atan angle of less than ninety degrees to the sidewall; and a tab footextending from the tab leg of the horizontal tab punched out of thesidewall and curving either away from or toward the horizontal hole inthe sidewall resulting from the horizontal tab punched out of thesidewall; where the end of vertical tab leg that is connected to thesidewall is substantially perpendicular to the end of the horizontal tableg that is connected to the sidewall; and where the structural studsare arranged such that their baseplates are substantially parallel toeach other and voids are formed between successive structural studs; anexterior concrete surface in which the tabs punched out of theexterior-facing sidewalls are embedded; and an interior concrete surfacein which the tabs punched out of the interior-facing sidewalls areembedded; where the exterior and interior concrete surfaces aresubstantially planar surfaces that are substantially parallel to eachother.

In some embodiments, one or more of the vertical holes is defined by abase side and a top side, the base side has a greater length than thetop side, and the vertical tab leg the extends from the base side; andone or more of the horizontal holes is defined by a base side and a topside, the base side has a greater length than the top side, and thehorizontal tab leg the extends from the base side. In other embodiments,one or more of the structural studs comprises a plurality of verticaltabs and resulting vertical holes and horizontal tabs and resultinghorizontal holes. In still other embodiments, the vertical tabs andvertical holes and the horizontal tabs and horizontal holes arepositioned in an alternating arrangement on the sidewall such that thereis a horizontal tab and horizontal hole between each vertical tab andvertical hole. In yet another embodiment, the horizontal holes and thevertical holes are spaced such that the distance between the centers ofsuccessive vertical and horizontal holes is less than about 6 inches,while in other embodiments, the horizontal holes and the vertical holesare spaced such that the distance between the centers of successivevertical and horizontal holes is about 4 inches.

The use of the term “or” in the claims is used to mean “and/or” unlessexplicitly indicated to refer to alternatives only or the alternativesare mutually exclusive, although the disclosure supports a definitionthat refers to only alternatives and “and/or.”

Throughout this application, the terms “substantially” and “about” aredefined as at least close to (and includes) a given value or state(preferably within 10% of, more preferably within 1% of, and mostpreferably within 0.1% of).

Following long-standing patent law, the words “a” and “an,” when used inconjunction with the word “comprising” in the claims or specification,denotes one or more, unless specifically noted.

As used in this specification and claim(s), the words “comprising” (andany form of comprising, such as “comprise” and “comprises”), “having”(and any form of having, such as “have” and “has”), “including” (and anyform of including, such as “includes” and “include”) or “containing”(and any form of containing, such as “contains” and “contain”) areinclusive or open-ended and do not exclude additional, unrecitedelements or method steps. As a result, a tilt-wall panel, device, ormethod that “comprises,” “has,” “contains,” or “includes” one or moreelements possesses those one or more elements, but is not limited topossessing only those one or more elements or steps. Likewise, anelement of a tilt-wall panel, device, or method that “comprises,” “has,”“contains,” or “includes” one or more features possesses those one ormore features, but is not limited to possessing only those one or morefeatures. Furthermore, a structure that is configured in a certain waymust be configured in at least that way, but also may be configured in away or ways that are not specified.

Descriptions of well-known processing techniques, components, andequipment are omitted so as not to unnecessarily obscure the presentmethods and devices in unnecessary detail. Other objects, features andadvantages of the present invention will become apparent from thefollowing detailed description. It should be understood, however, thatthe detailed description and the specific examples, while indicatingspecific embodiments of the invention, are given by way of illustrationonly, as various changes and modifications within the spirit and scopeof the invention will become apparent to those skilled in the art fromthis detailed description.

The claims are not to be interpreted as including means-plus- orstep-plus-function limitations, unless such a limitation is explicitlyrecited in a given claim using the phrase(s) “means for” or “step for,”respectively.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings illustrate by way of example and not limitation.Identical reference numerals do not necessarily indicate an identicalstructure. Rather, the same reference numeral may be used to indicate asimilar feature or a feature with similar functionality. Every featureof each embodiment is not always labeled in every figure in which thatembodiment appears, in order to keep the embodiments clear. The drawingsform part of the present specification and are included to furtherdemonstrate certain aspects of the present invention. The invention maybe better understood by reference to one or more of these drawings incombination with the description of illustrative embodiments presentedherein:

FIG. 1 is a partial isometric view of one embodiment of the structuralstuds used in the present tilt-wall panels.

FIG. 2 is a partial side view of one embodiment of the structural studsused in the present tilt-wall panels.

FIG. 3 is a front view of one embodiment of the structural studs used inthe present tilt-wall panels.

FIG. 4 is a partial top view of one embodiment of the structural studsused in the present tilt-wall panels.

FIG. 5 is a partial isometric view of another embodiment of thestructural studs used in the present tilt-wall panels.

FIG. 6 is a partial isometric view of another embodiment of thestructural studs used in the present tilt-wall panels.

FIG. 7 is a partial side view of another embodiment of the structuralstuds used in the present tilt-wall panels.

FIG. 8 is a front view of another embodiment of the structural studsused in the present tilt-wall panels.

FIG. 9 is a partial top view of another embodiment of the structuralstuds used in the present tilt-wall panels.

FIG. 10 is a partial cutaway exploded perspective view of one embodimentof the present tilt-wall panels.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

One embodiment of the structural studs used in the present tilt-wallpanels is partially shown in FIGS. 1-4. The structural stud comprises astud 101 having a baseplate 102, sidewalls 103 and 104 connected to thebaseplate 102, and tabs 105 and 106 punched out of the sidewalls. Thetabs 105 and 106 comprise tab legs 107 and 108 that are substantiallyplanar and are connected to the sidewalls 103 and 104 at one end of tablegs 107 and 108. The tab legs 107 and 108 project outwardly from thesidewalls 103 and 104 at an angle of less than ninety degrees to thesidewalls 103 and 104. Having the tab legs 107 and 108 project outwardlyat an angle of less than ninety degrees results in improved adhesionbetween the structural stud and the surrounding concrete. The tabs 105and 106 also comprise tab feet 109 and 110 extending from the tab legs107 and 108 and curving away from holes 111 and 112 in the sidewalls 103and 104 created by the tabs 105 and 106 punched out of the sidewalls 103and 104. Having the tab feet 109 and 110 curve away from the holes 111and 112 in the sidewalls 103 and 104 further results in improvedadhesion between the structural stud and the surrounding concrete.Having the tab feet 109 and 110 curve toward from the holes 111 and 112in the sidewalls 103 and 104 achieves a similar effect. In someembodiments, the holes 111 and 112 in the sidewalls 103 and 104 aredefined by base sides 113 and 114 and top sides 115 and 116, the basesides have a greater length than the top sides, and the tab legs 107 and108 extend from the base sides 113 and 114.

Another embodiment of the structural studs used in the present tilt-wallpanels is partially shown in FIG. 5. In this embodiment, the structuralstud 504 comprises a baseplate 506, a sidewall 508, a plurality of tabs510, 512, and 514 punched out of the sidewall 508, and a plurality ofholes 522, 524, and 526 created by the tabs 510, 512, and 514 punchedout of the sidewall 508. In some embodiments, the plurality of tabs 510,512, and 514 is spaced such that the gaps between successive ones of tableg connections 516, 518, and 520 are anywhere from about 1 to about 24inches, including about 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7,7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5,15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5, 19, 19.5, 20, 20.5, 21, 21.5,22, 22.5, 23, and 23.5 inches, or any range derivable within thesenumbers. In some embodiments, the gaps between successive ones of tableg connections 516, 518, and 520 are less than about six inches, whichfurther results in improved adhesion between the structural stud and thesurrounding concrete. In other embodiments the gaps between successiveones of tab leg connection 516, 518, and 520 are about four inches.

While FIG. 5 only depicts three tabs in one sidewall of the structuralstud, the number of tabs, the sizes of the tabs, and the spacing of thetabs in each of the sidewalls of the stud can vary depending on thesize, thickness, and tensile strength of the structural stud. Forexample, the embodiments described above where the gaps betweensuccessive tab leg connections are less than about six inches, and inparticular about four inches, encompass a structural stud where thewidth of the baseplate 506 is about 6 inches, the width of the sidewall508 is about 2 inches, and the stud is composed of steel that is 16gauge in thickness and has a tensile strength of 50 ksi (i.e.,kilo-pound per square inch). For studs of different sizes and/or steelthicknesses and tensile strengths, the sizes of the gaps can beproportionally scaled. Other steel thicknesses that are suitable for usein certain embodiments of the structural studs of the present inventioninclude 8, 9, 10, 11, 12, 14, 18, and 20 gauge steel. Other steeltensile strengths that are suitable for use in certain embodiments ofthe structural studs of the present invention include 33, 34, 35, 36,37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54,and 55 ksi, or any range derivable within these numbers.

With regard to the size and number of the tabs, in some embodiments, thesize and number of the tabs is such that the total surface area of thesidewall divided by the total surface area of the holes created by thetabs results in a ratio of less than about 9.6. More particularly, theratio is any of the following: 9.6, 9.5, 9.4, 9.3, 9.2, 9.1, 9.0, 8.9,8.8, 8.7, 8.6, 8.5, 8.4, 8.3, 8.2, 8.1, 8.0, 7.9, 7.8, 7.7, 7.6, 7.5,7.4, 7.3, 7.2, 7.1, 7.0, 6.9, 6.8, 6.7, 6.6, 6.5, 6.4, 6.3, 6.2, 6.1,6.0, 5.9, 5.8, 5.7, 5.6, 5.5, 5.4, 5.3, 5.2, 5.1, 5.0, 4.9, 4.8, 4.7,4.6, 4.5, 4.4, 4.3, 4.2, 4.1, 4.0, 3.5, 3.0, 2.5, 2.0, and 1.5, or anyrange derivable within these numbers.

In other embodiments, the size and number of tabs is such that the totalsurface area of the holes created by the tabs is greater than about 10%of the total surface area of the sidewall. More particularly, the totalsurface area of the holes created by the tabs is any of the followingpercentages of the total surface area of the sidewall: 10.1%, 10.2%,10.3%, 10.4%, 10.5%, 10.6%, 10.7%, 10.8%, 10.9%, 11.0%, 11.1%, 11.2%,11.3%, 11.4%, 11.5%, 11.6%, 11.7%, 11.8%, 11.9%, 12.0%, 12.1%, 12.2%,12.3%, 12.4%, 12.5%, 12.6%, 12.7%, 12.8%, 12.9%, 13.0%, 13.1%, 13.2%,13.3%, 13.4%, 13.5%, 13.6%, 13.7%, 13.8%, 13.9%, 14.0%, 14.1%, 14.2%,14.3%, 14.4%, 14.5%, 14.6%, 14.7%, 14.8%, 14.9%, 15.0%, 15.1%, 15.2%,15.3%, 15.4%, 15.5%, 15.6%, 15.7%, 15.8%, 15.9%, 16.0%, 17%, 18%, 19%,20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, or 70%, or any rangederivable within these numbers.

Another embodiment of the structural studs used in the present tilt-wallpanels is partially shown in FIGS. 6-9. In this embodiment, thestructural stud 201 comprises a baseplate 203, sidewalls 205 and 206, aplurality of vertical tabs 207, 208, 209, and 210 punched out of thesidewalls 205 and 206, a plurality of vertical holes 211, 212 (notshown), 213, and 214 (not shown) created by the vertical tabs 207, 208,209, and 210 punched out of the sidewalls 205 and 206, a plurality ofhorizontal tabs 215, 216, 217, and 218 punched out of the sidewalls 205and 206, and a plurality of horizontal holes 219, 220 (not shown), 221,and 222 (not shown) created by the horizontal tabs 215, 216, 217, and218 punched out of the sidewalls 205 and 206.

The vertical tabs 207, 208, 209, and 210 comprise tab legs 223, 224,225, and 226 that are substantially planar and are connected to thesidewalls 205 and 206 at one end of the tab legs 223, 224, 225, and 226.The tab legs 223, 224, 225, and 226 project outwardly from the sidewalls205 and 206 at an angle of less than ninety degrees to the sidewalls 205and 206. Having the tab legs 223, 224, 225, and 226 project outwardly atan angle of less than ninety degrees results in improved adhesionbetween the structural stud and the surrounding concrete. The verticaltabs 207, 208, 209, and 210 also comprise tab feet 227, 228, 229, and230 extending from the tab legs 223, 224, 225, and 226 and curving awayfrom vertical holes 211, 212 (not shown), 213, and 214 (not shown)created by the vertical tabs 207, 208, 209, and 210 punched out of thesidewalls 205 and 206. Having the tab feet 227, 228, 229, and 230 curveaway from the vertical holes 211, 212 (not shown), 213, and 214 (notshown) in the sidewalls 205 and 206 further results in improved adhesionbetween the structural stud and the surrounding concrete. Having the tabfeet 227, 228, 229, and 230 curve toward from the holes 211, 212 (notshown), 213, and 214 (not shown) in the sidewalls 205 and 206 achieves asimilar effect. In some embodiments, the vertical holes 211, 212 (notshown), 213, and 214 (not shown) in the sidewalls 205 and 206 aredefined by base sides 231, 232 (not shown), 233, and 234 (not shown) andtop sides 235, 236 (not shown), 237, and 238 (not shown), the base sideshave a greater length than the top sides, and the tab legs 223, 224,225, and 226 extend from the base sides 231, 232 (not shown), 233, and234 (not shown).

The horizontal tabs 215, 216, 217, and 218 comprise tab legs 239, 240,241, and 242 that are substantially planar and are connected to thesidewalls 205 and 206 at one end of the tab legs 239, 240, 241, and 242.The tab legs 239, 240, 241, and 242 project outwardly from the sidewalls205 and 206 at an angle of less than ninety degrees to the sidewalls 205and 206. Having the tab legs 239, 240, 241, and 242 project outwardly atan angle of less than ninety degrees results in improved adhesionbetween the structural stud and the surrounding concrete. The horizontaltabs 215, 216, 217, and 218 also comprise tab feet 243, 244, 245, and246 extending from the tab legs 239, 240, 241, and 242 and curvingtoward horizontal holes 219, 220 (not shown), 221, and 222 (not shown)created by the horizontal tabs 215, 216, 217, and 218 punched out of thesidewalls 205 and 206. Having the tab feet 243, 244, 245, and 246 curvetoward the horizontal holes 219, 220 (not shown), 221, and 222 (notshown) in the sidewalls 205 and 206 further results in improved adhesionbetween the structural stud and the surrounding concrete. Having the tabfeet 243, 244, 245, and 246 curve away from the holes 219, 220 (notshown), 221, and 222 (not shown) in the sidewalls 205 and 206 achieves asimilar effect. In some embodiments, the horizontal holes 219, 220 (notshown), 221, and 222 (not shown) in the sidewalls 205 and 206 aredefined by base sides 247, 248 (not shown), 249, and 250 (not shown) andtop sides 251, 252 (not shown), 253, and 254 (not shown), the base sideshave a greater length than the top sides, and the tab legs 239, 240,241, and 242 extend from the base sides 247, 248 (not shown), 249, and250 (not shown).

In the embodiment shown in FIGS. 6-9, base sides 247 and 249 and topsides 251 and 253 for horizontal holes 219 and 221 are substantiallyperpendicular to base sides 231 and 233 and top sides 235 and 237 forvertical holes 211 and 213. Thus, the ends of vertical tab legs 223 and225 connected to the sidewall 205 are substantially perpendicular to theends of horizontal tab legs 239 and 241 connected to the sidewall 205.This substantially perpendicular arrangement results in further improvedadhesion between the structural stud and the surrounding concrete andmakes panels that comprise the stud and concrete combination moreresistant to shear stress, particularly the high shear stress that canoccur in the taller walls that are often required for industrialbuildings.

In the embodiment shown in FIGS. 6-9, the vertical tabs 207 and 209 andvertical holes 211 and 213 and the horizontal tabs 215 and 217 andhorizontal holes 219 and 221 are positioned in an alternatingarrangement on sidewall 205 such that there is a horizontal tab andhorizontal hole between each vertical tab and vertical hole. In someembodiments, the horizontal holes and the vertical holes are spaced suchthat the distance between the centers of successive vertical andhorizontal holes is anywhere from about 1 to about 24 inches, includingabout 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9,9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16,16.5, 17, 17.5, 18, 18.5, 19, 19.5, 20, 20.5, 21, 21.5, 22, 22.5, 23,and 23.5 inches, or any range derivable within these numbers. In someembodiments, the distance between the centers of successive vertical andhorizontal holes is less than about 6 inches, which further results inimproved adhesion between the structural stud and the surroundingconcrete. In other embodiments the distance between the centers ofsuccessive vertical and horizontal holes is about four inches.

While FIGS. 6-9 only depict four tabs in each of the sidewalls of thestructural stud, the number of tabs, the sizes of the tabs, and thespacing of the tabs can vary depending on the size, thickness, andtensile strength of the structural stud. For example, the embodimentsdescribed above where the distance between the centers of successivevertical and horizontal holes is less than about six inches, and inparticular about four inches, encompass a structural stud where thewidth of the baseplate 203 is about 6 inches, the width of the sidewalls205 and 206 is about 2 inches, and the stud is composed of steel that is16 gauge in thickness and has a tensile strength of 50 ksi (i.e.,kilo-pound per square inch). For studs of different sizes and/or steelthicknesses and tensile strengths, the distances between the holes canbe proportionally scaled. Other steel thicknesses that are suitable foruse in certain embodiments of the structural studs of the presentinvention include 8, 9, 10, 11, 12, 14, 18, and 20 gauge steel. Othersteel tensile strengths that are suitable for use in certain embodimentsof the structural studs of the present invention include 33, 34, 35, 36,37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54,and 55 ksi, or any range derivable within these numbers.

A partial cutaway exploded view of one embodiment of the presenttilt-wall panels is depicted in FIG. 10. As shown in FIG. 10, thisembodiment comprises a plurality of vertical structural studs 901, 903,905, and 907, which have a plurality of tabs punched in their respectivesidewalls as described above regarding the studs depicted in FIGS. 1-5.In this embodiment, the plurality of tabs punched in the sidewalls ofthe vertical studs are spaced such that the gaps between successive onesof the tab leg connections are from about four to about six inches. Thevertical studs are arranged perpendicular to horizontal stud 909, whichhas a plurality of tabs punched in both of its sidewalls as describedabove for the studs depicted in FIGS. 1-5. In this embodiment, the panelfurther comprises a rigid insulation material 911 and 913 positioned inbetween each of the vertical studs. Examples of suitable rigidinsulation material are prefabricated extruded Dow®-brand insulationproducts. In contrast to the expensive two-inch layer of rigid boardinsulation that is required in the prior insulated tilt-wall panelsproviding a concrete interior surface due to their excessive thicknessand weight, any rigid insulation material can be used in the presentpanels as long as it is sturdy enough to withstand the weight of theconcrete used in the panel. Thus, it is possible for panels according tosome embodiments of the present invention to achieve twice theinsulation of prior insulated tilt-wall panels providing a concreteinterior surface at half the weight, which can lead to a reduction inthe cost required to produce the insulated panels of over seventy-fivepercent.

To further improve the insulating characteristics of the panel, thisembodiment further comprises (1) a rubberized insulation materialapplied to the tabs punched out of exterior-facing sidewalls 915, 917,919, and 921 of the vertical studs, which includes, by way of example,tabs 923, 925, 927, and 929, and (2) a radiant barrier 931 wrapped overthe tabs of the exterior-facing sidewall of the vertical studs. In oneembodiment, the radiant barrier comprises two sheets of foil andencapsulated air. This embodiment of the tilt-wall panels furthercomprises wire mesh 933 and 935 laid over both sidewalls of the verticalstuds. Finally, concrete surfaces 937 and 939 are formed over the wiremesh layers to complete the panel, with the tabs punched out ofinterior-facing sidewalls 941, 943, 945, and 947 embedded in interiorconcrete surface 937 and the tabs punched out of exterior-facingsidewalls 915, 917, 919, and 921 embedded in exterior concrete surface939. In this embodiment, the concrete thickness for each of the concretesurfaces is about two inches, although other thicknesses can be achievedand used.

Once the panels of the present invention are formed, they can then beraised such that they are substantially perpendicular to the ground toform a wall or part of a wall. In some embodiments, the panels furthercomprise lifting anchors laid in the voids formed between the verticalstuds 901, 903, 905, and 907 prior to embedding the studs and wire mesh933 and 935 in concrete to form the concrete surfaces 937 and 939, suchthat a portion of each lifting anchor is exposed once the concretesurfaces 937 and 939 are formed. The lifting anchors can then be used toraise the panel such that it is substantially perpendicular to theground. In other embodiments, the panels further comprise supportanchors laid in the voids formed between the vertical studs 901, 903,905, and 907 prior to embedding the studs and wire mesh 933 and 935 inconcrete to form the concrete surfaces 937 and 939, such that a portionof each support anchor is exposed once the concrete surfaces 937 and 939are formed. Supports can then attached to the support anchors. In someembodiments, anywhere from 1 to 36 lifting anchors and/or supportanchors can be used to raise and/or support a panel, including 2, 3, 4,5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23,24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, and 36 lifting anchorsand/or support anchors, or any range derivable within these numbers.Those of skill in the art can determine the appropriate number oflifting anchors and/or support anchors, placement of the lifting anchorsand/or support anchors, and manner of attaching the lifting anchors tothe lifting apparatus and/or the support anchors to the supportapparatus for a given panel size to safely and efficiently raise a panelinto position and/or support the panel once it is raised into positionwithout having the panel break under its own weight during the liftingand/or supporting process.

While FIG. 10 only depicts four vertical studs in the tilt-wall panel,each having ten vertical tabs punched at four- to six-inch spacing ineach sidewall, the number of studs, the number of tabs, the sizes of thetabs, the spacing of the tabs, and the orientation of the tabs can varydepending on the size, thickness, and tensile strength of the structuralstud, as discussed previously.

1. A tilt-wall panel comprising: a plurality of structural studs, eachcomprising: a baseplate; an exterior-facing sidewall and aninterior-facing sidewall connected by the baseplate; and a tab punchedout of each of the sidewalls, each tab comprising: a tab leg that issubstantially planar and is connected to the sidewall at one end of thetab leg, and that projects outwardly from the sidewall at an angle ofless than ninety degrees to the sidewall; and a tab foot extending fromthe tab leg and curving either away from or toward a hole in thesidewall created by the tab punched out of the sidewall; where thestructural studs are arranged such that their baseplates aresubstantially parallel to each other and voids are formed betweensuccessive structural studs; an exterior concrete surface in which thetabs punched out of the exterior-facing sidewalls are embedded; and aninterior concrete surface in which the tabs punched out of theinterior-facing sidewalls are embedded; where the exterior and interiorconcrete surfaces are substantially planar surfaces that aresubstantially parallel to each other.
 2. The tilt-wall panel of claim 1,where one or more of the holes is defined by a base side and a top side,the base side has a greater length than the top side, and the tab legextends from the base side.
 3. The tilt-wall panel of claim 1, where oneor more of the structural studs comprises a plurality of tabs.
 4. Thetilt-wall panel of claim 3, where the plurality of tabs is spaced suchthat the gap between successive tab leg connections to the sidewall isless than about six inches.
 5. The tilt-wall panel of claim 4, where thegap between successive tab leg connections to the sidewall is about fourinches.
 6. The tilt-wall panel of claim 1, further comprising aninsulation material in the voids formed between the structural studs. 7.The tilt-wall panel of claim 1, further comprising a rubberizedinsulation material applied to the tabs punched out of theexterior-facing sidewalls of the structural studs before the tabs wereembedded in concrete.
 8. The tilt-wall panel of claim 1, furthercomprising a radiant barrier wrapped over the tabs punched out of theexterior-facing sidewalls of the structural studs before the tabs wereembedded in concrete.
 9. The tilt-wall panel of claim 1, furthercomprising wire mesh laid over both sidewalls of the structural studsbefore the tabs punched out of the sidewalls were embedded in concrete.10. The tilt-wall panel of claim 1, further comprising lifting anchorslaid in the voids formed between the structural studs prior to embeddingthe tabs in concrete, such that a portion of each lifting anchor isexposed in one or both of the concrete surfaces.
 11. The tilt-wall panelof claim 1, further comprising support anchors laid in the voids formedbetween the structural studs prior to embedding the tabs in concrete,such that a portion of each support anchor is exposed in one or both ofthe concrete surfaces.
 12. A method of building a tilt-wall panel,comprising: obtaining a plurality of structural studs, each studcomprising: a baseplate; an exterior-facing sidewall and aninterior-facing sidewall connected by the baseplate; and a tab punchedout of each of the sidewalls, each tab comprising: a tab leg that issubstantially planar and is connected to the sidewall at one end of thetab leg, and that projects outwardly from the sidewall at an angle ofless than ninety degrees to the sidewall; and a tab foot extending fromthe tab leg and curving either away from or toward a hole in thesidewall created by the tab punched out of the sidewall; arranging thestructural studs such that their baseplates are substantially parallelto each other and voids are formed between successive structural studs;forming an exterior concrete surface in which the tabs punched out ofthe exterior-facing sidewalls are embedded; and forming an interiorconcrete surface in which the tabs punched out of the interior-facingsidewalls are embedded; where the exterior and interior concretesurfaces are substantially planar surfaces that are substantiallyparallel to each other.
 13. The method of claim 12, further comprising:laying lifting anchors in the voids formed between the structural studsprior to embedding the tabs in concrete, such that a portion of eachlifting anchor is exposed once the concrete surfaces are formed.
 14. Themethod of claim 12, further comprising: laying support anchors in thevoids formed between the structural studs prior to embedding the tabs inconcrete, such that a portion of each support anchor is exposed once theconcrete surfaces are formed.
 15. The method of claim 12, furthercomprising placing an insulation material in the voids formed betweenthe structural studs.
 16. The method of claim 12, further comprisingapplying a rubberized insulation material to the tabs punched out of theexterior-facing sidewalls of the structural studs prior to embedding thetabs in concrete.
 17. The method of claim 12, further comprisingwrapping a radiant barrier over the tabs punched out of theexterior-facing sidewalls of the structural studs prior to embedding thetabs in concrete.
 18. The method of claim 12, further comprising layingwire mesh over both sidewalls of the structural studs prior to embeddingthe tabs punched out of the sidewalls in concrete.
 19. A tilt-wall panelcomprising: a plurality of structural studs, each comprising: abaseplate; an exterior-facing sidewall and an interior-facing sidewallconnected by the baseplate; a vertical tab punched out of each of thesidewalls and a vertical hole resulting from the vertical tab, the tabcomprising: a tab leg that is substantially planar and is connected tothe sidewall at one end of the tab leg, and that projects outwardly fromthe sidewall at an angle of less than ninety degrees to the sidewall;and a tab foot extending from the tab leg of the vertical tab punchedout of the sidewall and curving either away from or toward the verticalhole in the sidewall resulting from the vertical tab punched out of thesidewall; and a horizontal tab punched out of each of the sidewalls anda horizontal hole resulting from the horizontal tab, the tab comprising:a tab leg that is substantially planar and is connected to the sidewallat one end of the tab leg, and that projects outwardly from the sidewallat an angle of less than ninety degrees to the sidewall; and a tab footextending from the tab leg of the horizontal tab punched out of thesidewall and curving either away from or toward the horizontal hole inthe sidewall resulting from the horizontal tab punched out of thesidewall; where the end of vertical tab leg that is connected to thesidewall is substantially perpendicular to the end of the horizontal tableg that is connected to the sidewall; and where the structural studsare arranged such that their baseplates are substantially parallel toeach other and voids are formed between successive structural studs; anexterior concrete surface in which the tabs punched out of theexterior-facing sidewalls are embedded; and an interior concrete surfacein which the tabs punched out of the interior-facing sidewalls areembedded; where the exterior and interior concrete surfaces aresubstantially planar surfaces that are substantially parallel to eachother.
 20. The tilt-wall panel of claim 19, where: one or more of thevertical holes is defined by a base side and a top side, the base sidehas a greater length than the top side, and the vertical tab leg theextends from the base side; and one or more of the horizontal holes isdefined by a base side and a top side, the base side has a greaterlength than the top side, and the horizontal tab leg the extends fromthe base side.
 21. The tilt-wall panel claim 19, where one or more ofthe structural studs comprises a plurality of vertical tabs andresulting vertical holes and horizontal tabs and resulting horizontalholes.
 22. The tilt-wall panel of claim 21, where the vertical tabs andvertical holes and the horizontal tabs and horizontal holes arepositioned in an alternating arrangement on the sidewall such that thereis a horizontal tab and horizontal hole between each vertical tab andvertical hole.
 23. The tilt-wall panel of claim 22, where the horizontalholes and the vertical holes are spaced such that the distance betweenthe centers of successive vertical and horizontal holes is less thanabout 6 inches.
 24. The tilt-wall panel of claim 23, where thehorizontal holes and the vertical holes are spaced such that thedistance between the centers of successive vertical and horizontal holesis about 4 inches.
 25. The tilt-wall panel of claim 19, furthercomprising an insulation material in the voids formed between thestructural studs.
 26. The tilt-wall panel of claim 19, furthercomprising a rubberized insulation material applied to the tabs punchedout of the exterior-facing sidewalls of the structural studs before thetabs were embedded in concrete.
 27. The tilt-wall panel of claim 19,further comprising a radiant barrier wrapped over the tabs punched outof the exterior-facing sidewalls of the structural studs before the tabswere embedded in concrete.
 28. The tilt-wall panel of claim 19, furthercomprising wire mesh laid over both sidewalls of the structural studsbefore the tabs punched out of the sidewalls were embedded in concrete.29. The tilt-wall panel of claim 19, further comprising lifting anchorslaid in the voids formed between the structural studs prior to embeddingthe tabs in concrete, such that a portion of each lifting anchor isexposed in one or both of the concrete surfaces.
 30. The tilt-wall panelof claim 19, further comprising support anchors laid in the voids formedbetween the structural studs prior to embedding the tabs in concrete,such that a portion of each support anchor is exposed in one or both ofthe concrete surfaces.